Hermetically seated controlled impedance feedthrough assembly

ABSTRACT

An assembly for passing controlled impedance electrical signals between two different environments via feedthroughs in an electrically-conductive feedthrough block. The feedthrough has a signal coupling, a dielectric spacer surrounding the signal coupling, and a ground coupling surrounding the dielectric. The feedthrough is sealed to hermetically separate the two environments. One or both ends of the dielectric are recessed from the face of the block forming a gap. The gaps is filled with a potting material to form the hermetic seal.

The present application is a continuation of U.S. patent applicationSer. No. 16/948,419 which claims the benefit of U.S. Provisional PatentApplication No. 62/901,297, both of which are hereby incorporated byreference in their entireties.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTINGCOMPACT DISK APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to electrical cable feedthroughassemblies, more particularly, to controlled-impedance cablefeedthroughs which are generally used to transmit high-frequency signalsbetween different physical environments.

2. Description of the Related Art

In some scenarios, signals must be fed between different environments.Examples include between environments with different atmosphere gasses,environments of different atmospheric pressures, and environments ofdifferent levels of sterility. In such cases, the interface must behermetically sealed so that the environments do not intermix or so thatone environment does not contaminate the other.

In the current state of the art, individual coaxial connectors, such asSMAs or SMPs, are used to transmit signals between environments. Theseconnectors are fairly large, 0.25 inch to 0.5 inch in diameter. Sincethey cannot be any closer to each other than their largest diameter, thenumber of connectors per unit area separating the environments, thedensity, is rather low.

BRIEF SUMMARY OF THE INVENTION

The present specification describes an assembly for passing signalsbetween two different environments. The signals, which are typically RF,are passed through a first connector in the first environment, throughfeedthroughs in a flange that separates the two environments, andthrough a second connector in the second environment. Each connectorterminates one or more controlled-impedance cables.

The connectors has several embodiments, representative ones of whichhave an anchor block for securing the cables, compliant signal contactsfor making electrical connections between the cable signal conductorsand the feedthroughs, optional compliant ground contacts for makingelectrical connections between the cable shields and the feedthroughs,and a plate mounted to the anchor block 88 that holds the contacts.

An electrically conductive anchor block provides a common ground for thecables that are either permanently or removably attached to the anchorblock. Alternatively, the anchor block is non-conductive and merelyprovides an anchor for the cables that are removably attached.

The connector can be designed for use with any number of differentcompliant contacts. A plate holds the contacts and can be composed of anelectrically conductive or electrically insulative material. The plateabuts the anchor block face when the connector is assembled andgenerally abuts the feedthrough block when the connector is connected tothe feedthrough block. The signal contact is captured in a throughaperture in the plate. If the plate is conductive, the signal contact isinsulated from the plate. Prior to assembling the plate to the anchorblock, the contact points of the signal contact extend from each side ofthe plate. Each ground contact is captured in a ground through aperture.Prior to assembling the plate to the anchor block, the contact points ofthe ground contact extend from each side of the plate.

The signals travel through the flange via feedthroughs in a feedthroughblock. The feedthrough has three components: a signal coupling, adielectric surrounding the signal coupling, and a ground couplingsurrounding the dielectric. If the block is electrically insulating, theblock itself can act as the dielectric. If the block is electricallyconductive, a separate dielectric is required.

A feedthrough without a separate dielectric has a signal throughaperture in the block for a signal link, which is an electricallyconductive wire or pin. The ends of the signal link are the contactpoints for the signal contacts of the connectors. Optionally, the signallink and signal aperture are shaped to prevent the signal link frombeing pushed through the signal aperture during installation or if thefirst environment is at a higher pressure than the second environment.

A feedthrough with a separate dielectric has a spacer through aperturein the block with the dielectric in the form of a dielectric spacer.Optionally, the spacer aperture and spacer are shaped to prevent thespacer from being pushed through the spacer aperture during installationor if the first environment is at a higher pressure than the secondenvironment. The spacer has a signal through aperture for the signallink.

Typically, the aperture, spacer, and signal link are sized to provideimpedance matching for the signals using methods that are well-known inthe art. For an accurate impedance match, the dielectric must besurrounded by the system ground plane. If the block is electricallyconductive, no special accommodation for the ground signal is needed. Anon-conductive block must feed the ground signal through the block by aground coupling.

The ground coupling can include discrete electrically conductive groundlinks that extend through ground apertures in the block. The appropriatenumber of ground links surround the signal link. The ground links areelectrically conductive wires or pins. Alternatively, the ground linksare plated vias. In another configuration, the ground coupling is anelectrically conductive ground ferrule installed in a ground ferrulethrough aperture in the block that surrounds the spacer. In anotherconfiguration, the wall of the spacer aperture is coated with aconductive material.

The various components are installed with a hermetic seal tohermetically separate the two environments. In one method, the variouscomponents are press fit into the corresponding apertures, leaving nogap between adjacent components. Alternatively, the spacer is moldedaround the signal link and press fit into the spacer through aperture.

In another method, the spacer is shorter than the spacer aperture sothat one or both faces of the spacer are recessed from the correspondingblock surface, thereby leaving a gap between the spacer and the blocksurface. One or both of the gaps are potted to seal the spacer apertureand around the signal link, thereby producing a hermetic seal. Thetypical potting material is a two-part epoxy. The minimum depth for eachgap depends on the environment and the potting material and is typicallynot less than 0.01 inch. Plated vias are hermetically sealed by fillingthem with the potting material or solder.

One method of potting involves applying a vacuum to one surface of theblock and allowing the vacuum to pull the potting material from theopposite side, thereby forcing the potting material into the gap and allof the interfaces between components. The vacuum assures that thepotting material is forced into all of the spaces that would provide aleak path. Alternatively, pressure is applied to the potting material atone surface to push the potting material into all of the spaces thatwould provide a leak path.

The present invention contemplates that the flange is the block, thatis, the feedthroughs extend through the flange itself. Alternatively,the block is an independent component that is hermetically sealed intoan opening in the flange.

Objects of the present invention will become apparent in light of thefollowing drawings and detailed description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and object of the presentinvention, reference is made to the accompanying drawings, wherein:

FIG. 1 is a cross-section of one embodiment;

FIG. 2 is a detail of FIG. 1 ;

FIG. 3 is a cross-sectional view of a section of a configuration of theconnector of FIG. 1 with permanently attached cables;

FIG. 4 is a cross-sectional view of a section of a configuration of theconnector with removable cables;

FIG. 5 is a cross-sectional view of a section of another configurationof the connector with removable cables;

FIG. 6 is a cross-sectional view of a section of another configurationof the connector with removable cables;

FIG. 7 is a cross-sectional view of one configuration of the plate witha portion of the anchor block and cable;

FIG. 8 is a cross-sectional view of another configuration of the platewith a portion of the anchor block and cable;

FIG. 9 is a cross-sectional view of an insulative plate with fuzz buttoncontacts;

FIG. 10 is a cross-sectional view of an insulative plate with conductiverubber contacts;

FIG. 11 is a cross-sectional view taken at E-E of FIG. 10 ;

FIG. 12 is a cross-sectional view taken at F-F of FIG. 11 ;

FIG. 13 is bottom view of an insulative plate with embedded stamped oretched contacts;

FIG. 14 is a detail view of the bottom of the coax cable terminationassembly of FIG. 13 taken at H;

FIG. 15 is a cross-sectional view of the plate of FIG. 13 ; and

FIG. 16 is a cross-sectional view of an insulative plate with embeddedstamped or etched contacts with one side mated to the cables and thecontacts compressed.

FIG. 17 is a cross-section of a block separate from the flange;

FIG. 18 is a cross-section of a basic feedthrough without a separatedielectric;

FIG. 19 is a top view of the feedthrough of FIG. 18 ;

FIG. 20 is a cross-section of a feedthrough with an alternateconfiguration of the signal link and signal aperture;

FIG. 21 is a cross-section of a feedthrough with an alternateconfiguration of the signal link and signal aperture;

FIG. 22 is a cross-section of a basic feedthrough;

FIG. 23 is a top view of the feedthrough of FIG. 22 ;

FIG. 24 is a cross-section of a feedthrough with alternateconfigurations of several components;

FIG. 25 is a top view of the feedthrough of FIG. 24 ;

FIG. 26 is a cross-section of a feedthrough with alternateconfigurations of several components;

FIG. 27 is a cross-section of a feedthrough with alternateconfigurations of several components;

FIG. 28 is a cross-sectional view of a feedthrough with ground links;

FIG. 29 is a top view of a feedthrough with ground links surrounding thesignal link and spacer;

FIG. 30 is a cross-sectional view of a PCB block with ground links;

FIG. 31 is a top view of a feedthrough with ground links in a groundplane;

FIG. 32 is a cross-sectional view of a feedthrough with a groundferrule;

FIG. 33 is a cross-section of a feedthrough with a plated aperture andground pads;

FIG. 34 is a cross-section of the block as part of the flange;

FIG. 35 is a top view of a flange as the block;

FIG. 36 is a top view of a flange with independent blocks;

FIG. 37 is a top view of the flange with a PCB as the block;

FIG. 38 is a cross-sectional view showing connection of the connectorsto the feedthrough block;

FIG. 39 is a cross-sectional view of another embodiment;

FIG. 40 is a cross-sectional view of the embodiment of FIG. 39 with aconnector attached; and

FIG. 41 is another cross-sectional view of the embodiment of FIG. 39with a connector attached.

DETAILED DESCRIPTION OF THE INVENTION

The present specification describes an assembly 10 for passing signalsbetween a first environment 1 and a second environment 2 separated by abarrier 3. The two environments 1, 2 can be different in many respects.For example, there can be pressure, temperature, or chemical compoundson either side of the barrier 3 which are not to be mixed in someapplications. An example of such a situation is feeding data into andout of a cold computing environment, such as a quantum computingenvironment. The first environment 1 is typically at normal atmosphericpressure and room temperature. In a quantum computing environment, thesecond environment 2 is at a near perfect vacuum. The region of thesecond environment 2 closest to the first environment 1 is near roomtemperature and the temperature of the region farthest from the firstenvironment 1 is kept between 4 Kelvin and 4 milliKelvin.

As shown in FIGS. 1 and 2 , the signals are passed between theenvironments 1, 2 through a first connector 14 in the first environment1, a flange 12 that separates the two environments 1, 2, and a secondconnector 16 in the second environment 2. The signals are typicallyradio frequency, RF, signals. Signal speeds can be as low as a fewhundred MHz to as high as 70 GHz depending on the application, thoughthe upper end of the frequency range with which the present inventioncan be employed is constantly being improved upon.

Each connector 14, 16 terminates one or more controlled-impedance cables20. A controlled-impedance coaxial cable 20 has a signal conductor 22surrounded by a dielectric 24 with a ground reference shield 26 outsidethe dielectric 24. Optionally, a sheath 28 covers the shield 26. Acontrolled-impedance twin-axial cable 20 has two signal conductors 22surrounded by a dielectric 24 with a ground reference shield 26 outsidethe dielectric 24 and a sheath 28 covering the shield 26. In order forthe cable 20 to be terminated properly, the cable ground shield 26 mustbe electrically coupled to the connector 14,16. Optionally, a ferrule 90can be installed on the ground shield 26, as in FIG. 2 .Controlled-impedance cables 20 with more than two signal conductors 22are available. Although not specifically described, the presentinvention can be adapted to accommodate cables 20 having any number ofsignal conductors 22.

The flange 12 removably mounts into an opening in the barrier 3 thatseparates the two environments 1, 2. The flange 12 is mounted in anymanner that provides an acceptable hermetic seal between the flange 12and the barrier 3. Methods of mounting are well-known in the industry.Alternatively, the barrier 3 incorporates the flange 12, that is, thebarrier 3 and flange 12 are not separate components.

The signals travel through the flange 12 via feedthroughs 11 in afeedthrough block 30. The connectors 14, 16 provide the interfacebetween the controlled-impedance coaxial cables (hereinafter, simply“cable”) 20 and the feedthroughs 11. Different configurations of theconnectors 14, 16 are described in U.S. Pat. Nos. 8,926,342 and9,160,151, both of which are incorporated herein by reference. Severalof the configurations are summarized below. Only one connector 14 isreferenced hereinafter.

The connector 14 has several embodiments, representative ones of whichhave an anchor block 88 for securing the cables 20, compliant signalcontacts 86 for making electrical connections between the cable signalconductors 22 and the feedthroughs 11, optional compliant groundcontacts 87 for making electrical connections between the cable shields26 and the feedthroughs 11, and a plate 89 mounted to the anchor block88 that holds the contacts 86, 87.

In one configuration, the anchor block 88 is electrically conductive andprovides a common ground for the cables 20 that are permanentlyattached, as in FIG. 3 . The ground shields 26 of all of the cables 20are electrically connected to the anchor block 88 in holes 91 in theanchor block 88. Any adequate method can be used, including soldering,crimping, potting with a conductive adhesive, insert molding the anchorblock 88 with the cable 20 in place at the time of molding, and pressfitting a rigidized, for example, pretinned, ground shield 26 into thehole 91.

Once the cables 20 are anchored in the anchor block 88, the face 92 ofthe anchor block 88, the signal conductors 22, and the dielectrics 24are properly dressed to make reliable electrical contacts with thecompliant contacts 86, 87. The anchor block face 92, signal conductor22, and dielectric 24 may need to be polished and planarized by somemechanical means, such as by milling, grinding, or sanding, in order tomake sure that the cable center conductors 22 and dielectrics 24 arepositioned at a known depth with respect to the anchor block face 92, inthis case flush with the anchor block face 92. The anchor block face 92and signal conductors 22 may also require noble metal plating to preventthe polished surface from oxidizing or otherwise degrading so as toinhibit acceptable electrical connection of the contacts 86, 87 to thesignal conductors 22 and the anchor block 88.

In another configuration, the anchor block 88 is either conductive ornonconductive and merely provides an anchor for the cables 20 that areremovably attached. Methods of removably attaching the cable 20 to theanchor block 88 are shown in FIGS. 4-6 . These methods permitreplacement of individual cables 20 so the entire assembly does not haveto be replaced.

The first method, shown in FIG. 4 , calls for attaching a ferrule at ornear the end of the cable 20 for dressing the cable end. The sheath 28is stripped back and a threaded ferrule 94 is slipped over the shield26. The ferrule 94 is attached to the cable 20 by soldering, crimping,or other mechanical means that electrically couples the ferrule 94 tothe shield 26. The ferrule face 95, signal conductor 22, and dielectric24 are then dressed as described above with reference to the anchorblock 88. The ferrule 94 is threaded into a threaded hole 96 in theanchor block 88 until the signal conductor 22 is pressed against thesignal contact 86 in order to produce an electrical connection betweenthe signal conductor 22 and the signal contact 86.

The second method of removably attaching the cable 20 to the anchorblock 88 calls for the use of a twist-lock attachment 100, as shown inFIG. 5 . A twist-lock component 102 is slipped over the cable 20 suchthat the component 102 can slide freely over the cable 20. A coil spring104 is slipped over the cable 20. After the sheath 28 is stripped back,a ferrule 106 is attached to the shield 26 by soldering, crimping, orother mechanical means that electrically couples the ferrule 106 to theshield 26. The ferrule face 108, signal conductor 22, and dielectric 24are then dressed as described above with reference to the anchor block88.

The ferrule 106/cable 20 is inserted into a hole 110 in the anchor block88. Protrusions 112 from the twist-lock component 102 slide down opposednotches, not shown, in the sides of the hole 110 until they align withan annular depression 114 in the hole 110. With this alignment, thespring 104 is compressed so that it presses the signal conductor 22 tothe signal contact 86 in order to produce an electrical connectionbetween the signal conductor 22 and the signal contact 86. Thetwist-lock component 102 is turned so that the protrusions 112 arecaptured by the annular depression 114, thereby retaining the cable 20in the hole 110.

Another method of removably attaching the cable 20 to the anchor block88 is shown in FIG. 6 . A ferrule 120 is attached to the cable 20 anddressed as described above. The ferrule 120 has an annular ridge 122either at the end 124 of the ferrule 120 or away from the end 124, as inFIG. 6 . The anchor block 88 has two sections, a bottom section 126, anda top section 128. The upper end of the cable hole 130 in the bottomsection 126 has an annular groove 132. When the ferrule 120/cable 20assembly is inserted into the cable hole 130, the ridge 122 fits intothe groove 132 with the ferrule face 134, signal conductor 22, anddielectric 24 flush with the block face 92. The block top section 128 isinstalled on the bottom section 126 and attached via screws, clips, orany other acceptable method. The top section 126 captures the ferrule120/cable 20 assembly in the anchor block 88. Optionally, the ridge 122and groove 132 can be keyed to prevent the ferrule 120/cable 20 assemblyfrom rotating in the cable hole 130.

In some situations, particularly with removable attachments, the signalconductor 22 and/or dielectric 24 may not be exactly flush with theanchor block face 92, that is, it may be slightly recessed into orprotruding from the anchor block face 92. That recession or protrusioncan be as much as 0.05 inch. The present specification and claims usethe term, “flush”, to indicate that the signal conductor 22 anddielectric 24 are actually flush with, slightly recessed into, orslightly protruding from the anchor block face 92 by as much as 0.05inch.

The connector 14 can be designed for use with any number of differentcompliant contacts, including, but not limited to, skewed coil contacts,fuzz button contacts, conductive rubber contacts, and conductive stripcontacts. FIGS. 3-8 show the connector as designed for use with skewedcoil contacts. Skewed coil contacts of various types and configurationsare described in U.S. Pat. Nos. 7,126,062 and Re41,663, both of whichare incorporated herein by reference. Briefly, the skewed coil contactincludes a coil of conductive, inherently elastic wire with a pair ofoppositely extending leads. The leads extend in a direction angled fromthe coil axis. During compression, the coil loops are electricallyshorted together while they slide along each other.

The plate 89, shown in FIGS. 7 and 8 , holds the contacts 86, 87 and canbe composed of an electrically conductive or electrically insulativematerial.

The plate 89 has a block surface 154 that abuts the anchor block face 92when the connector 14 is assembled and a feedthrough surface 156 thatgenerally abuts the feedthrough block 30 when the connector 14 isconnected to the feedthrough block 30. Typically, the plate 89 isattached to the anchor block face 92 by screws 216.

As shown in FIG. 7 , the signal contact 86 is captured in a throughaperture 160 in the plate 89. The signal through aperture 160 has alarger center section 166 that narrows to a smaller signal block opening168 in the block surface 154 and to a smaller signal feedthrough opening170 in the feedthrough surface 156. The coil 140 of the contact 86 iscaptured in the center section 166. Prior to assembling the plate 89 tothe anchor block 88, the block contact point 142 of the signal contact86 extends from the signal block opening 168. Prior to connecting theconnector 14 to the feedthrough block 30, the feedthrough contact point144 of the signal contact 86 extends from the signal feedthrough opening170.

If the plate 89 is conductive, the signal through aperture 160 is withinan insulating plug 162 that prevents the signal contact 86 fromelectrically shorting to the plate 89. The plug 162 is typically madefrom an insulating plastic. The plug 162 fits in a signal through hole164 in the plate 89.

After the plate 89 is assembled to the anchor block 88, each signalblock opening 168 is aligned with its corresponding cable hole 91 in theanchor block 88.

Each ground contact 87 is captured in a ground through aperture 190.Each ground through aperture 190 has a larger center section 192 thatnarrows to a smaller ground block opening 194 in the block surface 154and to a smaller ground feedthrough opening 196 in the feedthroughsurface 156. The coil 146 of the ground contact 87 is captured in thecenter section 192. Prior to assembling the plate 89 to the anchor block88, the block contact point 148 of the ground contact 87 extends fromthe ground block opening 194. Prior to connecting the connector 14 tothe feedthrough block 30, the feedthrough contact point 150 of theground contact 87 extends from the ground feedthrough opening 196.

When composed of a conductive material, the plate 89 electricallycouples the ground contacts 87, thus providing more precise impedancematching to the signal contact 86.

In the configuration of FIG. 7 , the plate 89 has two mirror imagesheets 200, 202. The bottom sheet 200 has the feedthrough openings 170,196 and half of the center sections 166, 192, and the top sheet 202 hasthe block openings 168, 194 and half of the center sections 166, 192.The contacts 86, 87 are placed in the center section 166, 192 of onesheet 200 and the sheets 200, 202 are sandwiched together to capture thecontacts 86, 87.

In the configuration of FIG. 8 , the plate 89 has a bottom sheet 204with the feedthrough openings 170, 196 and the entirety of the centersections 166, 192, and a top sheet 206 with only the block openings 168.The contacts 86, 87 are placed in the center section 166, 192 of thebottom sheet 204 and the sheets 204, 206 are sandwiched together tocapture the contacts 86, 87.

When an insulating plug 162 is used, it may be press fit into thethrough hole 164 in the plate 89 or it may be bonded into the throughhole 164 with an adhesive. Alternatively, as shown in FIG. 7 , the plug162 has two parts 174, 176, each of which fit into one plate sheet 200,202. Mating shoulders 178, 180 retain the plug parts 174, 176 in theplate sheets 200, 202. Alternatively, as shown in FIG. 8 , the plug 162is has a lower part 182 and an upper part 184, which fit into the lowersheet 204 and upper sheet 206, respectively. Mating shoulders 186, 188retain the plug parts 182, 184 in the plate sheets 204, 206.

As mentioned above, fuzz button contacts can be employed. As shown inFIG. 9 , the fuzz button contact 220 is cylindrical. The plate 89 has athrough aperture 160 that is narrower at the center than the ends, as at224. The contact 220 is forced into the aperture 160. The length of thecontact 220 is such that the ends 226 extend from the plate 89.

As mentioned above, conductive rubber contacts can be employed. As shownin FIGS. 10-12 , the conductive rubber contact 230 for the signalcontact 86 can be cylindrical with a centrally located annulardepression 232. The plate 89 has a through aperture 160 with a centrallylocated annular protrusion 236. The conductive rubber contact 230 isradially compressed and placed in the aperture 160 such that theprotrusion 236 fits into the depression 232 to retain the contact 230 inthe aperture 160. The length of the contact 230 is such that the ends238 extend from the plate 89.

The conductive rubber contact for the ground contact 87 can be of thesame structure as the signal contact 86. Alternatively, the conductiverubber contact 242 for the ground contact 87 is circular, surroundingthe signal contact 86, as in FIG. 11 . The conductive rubber contact 242has a circular top sheet 244 adjacent to the anchor block 88 and acircular bottom sheet 246 for interfacing to the feedthrough block 30.The two sheets 244, 246 are electrically connected by a plurality ofplugs 248 in through apertures 250 in the plate 89. The number of plugs248 can vary by application and is typically four or eight spaced evenlyaround the signal contact 230. As with the signal contact 230, each plug248 has an annular depression 252 that fits into an annular protrusion254 for retention. Knobs 256 extending from the sheets 244, 246 intodepressions 258 in the plate 89, as in FIG. 12 , to help retain thesheets 244, 246 in position.

As mentioned above, conductive strip contacts can be employed. In FIGS.13-16 , the contact 270 is a strip of conductive material in a C shape.The contact can be formed by chemical etching, by stamping and forming,or by any other means practical. The contact 270 is captured in athrough aperture 160 in the plate 89. In their quiescent state, thecontact leads 272 extend outwardly of the plate 89, as in FIG. 15 . Whenthe anchor block 88 is attached to the plate 89, the upper lead 272deforms toward the plate 89 and into a depression 276, shown in FIG. 16, thereby providing electrical contact by the signal contact 86 to thesignal conductor 22 and by the ground contacts 87 to the anchor block88. When the assembly is connected to the feedthrough block 30, thelower lead 274 deforms toward the plate 89 and into a depression 278.

As indicated above, the signals travel through the flange 12 viafeedthroughs 11 in a feedthrough block 30, shown in FIGS. 1, 2, 17, and34 . The first surface 38 of the block 30 is designed to tolerate thefirst environment 1 and the second surface 40 of the block 30 isdesigned to tolerate the second environment 2.

The feedthrough block 30 has a feedthrough 11 for each signal thatpasses between the two environments 1, 2 through the flange 12. In orderto accurately pass a controlled impedance signal, the feedthrough 11requires at least three components: a signal coupling 61, a dielectric53 surrounding the signal coupling 61, and a ground coupling 70surrounding the dielectric 53.

The feedthrough 11 has two different configurations that differ based onthe materials of which the block 30 is composed. If the block 30 iscomposed of an electrically insulating material, the block 30 itself canact as the dielectric 53. If the block 30 is composed of an electricallyconductive material, a separate dielectric 53 is required.

A feedthrough 11 without a separate dielectric is shown in FIGS. 18 and19 . The feedthrough 11 has a signal through aperture 43 in the block 30that extends between a first opening 44 in a first surface 38 of theblock 30 and a second opening 45 in a second surface 40 of the block 30.As shown in FIG. 19 , the signal through aperture 43 is typically round,but can be other shapes.

The signal coupling 61 includes a signal link 62 that extends througheach signal aperture 43. The signal link 62 is an electricallyconductive wire or pin and can be composed of any electricallyconductive material adequate to the application. Typically, the signallink 62 will be composed of a copper alloy. In one configuration, thesignal link 62 is composed of beryllium copper plated with gold overnickel. If a nonmagnetic signal link 62 is desired, gold platedberyllium copper can be used. The signal link 62 can also be composed ofnon-electrically conductive materials as long as the signal link 62 canconduct electricity. For example, the signal link 62 can be composed ofa non-electrically conductive plastic or composite that is embedded orcoated with electrically conductive materials that render the signallink 62 electrically conductive.

The signal link 62 has a first end 65 at the block first surface 38 anda second end 66 at the block second surface 40. The signal link ends 65,66 are the contact points for the signal contacts 86 of the connectors14, 16. Optionally, the signal ends 65, 66 are flush with thecorresponding block surface 38, 40. Due to inaccuracies and tolerancesin the manufacturing process, the signal link ends 65, 66 may not beexactly flush with the corresponding block surface 38, 40, that is, theymay be slightly recessed into or protruding from the corresponding blocksurface 38, 40. Typically, the recession is not more than 0.0005 inchand the protrusion is not more than 0.001 inch, but can be as much as0.05 inch. If the protrusion or recession is greater than allowable, theaffected signal link end 65, 66 and the corresponding block surface 38,40 can be polished and planarized by some mechanical means, such as bymilling, grinding, or sanding, in order to make sure that the signallink end 65, 66 is at a known depth with respect to the block surface38, 40, in this case flush with the ground block face 20. The polishedends 65, 66 may also require noble metal plating to prevent them fromoxidizing or otherwise degrading so as to inhibit acceptable electricalconnections.

The present specification and claims use the term, “flush”, to indicatethat the signal link ends 65, 66 are actually flush with, slightlyrecessed into, or slightly protruding from the corresponding blocksurface 38, 40 by as much as 0.05 inch.

The signal link 62 has a cross-sectional shape that allows a proper fit,mechanically and electrically, in the signal aperture 43. In thefigures, the signal aperture 43 and signal link 62 are both round.However, as long as the junction is structurally sound, the signalaperture 43 and the signal link 62 can be different cross-sectionalshapes. For example, the signal aperture 43 can be round and the signallink 62 can be octagonal.

Optionally, the signal link 62 and signal aperture 43 are shaped toprevent the signal link 62 from being pushed through the signal aperture43 during installation or if the first environment 1 is at a higherpressure than the second environment 2. In general, the diameter of thesignal link first end 65 is larger than a diameter of signal aperture43. In one configuration, shown in FIG. 20 , the signal link first end65 has a head 63 that has a larger diameter than the rest of the signallink 62 and the signal aperture 43. In another configuration, shown inFIG. 21 , the signal link 62 is a truncated cone rather thancylindrical. The signal aperture 43 is shaped to match such that, whenthe signal link 62 is securely within the signal aperture 43, each end65, 66 is at the corresponding block surface 38, 40. Any othergeometries that prevent the signal link 62 from being pushed through thesignal aperture 43 are contemplated by the present invention.

The ground coupling 70 is discussed below.

As indicated above, if the block 30 is composed of an electricallyconductive material, a separate dielectric 53 is required, as shown inFIGS. 22-25 . A separate dielectric 53 can also be used if the block 30is composed of an electrically insulating material that does not havethe necessary dielectric characteristics.

The feedthrough 11 has a spacer through aperture 32 in the block 30 thatextends between a first opening 34 in a first surface 38 of the block 30and a second opening 36 in a second surface 40 of the block 30. As shownin FIGS. 23 and 25 , the spacer through aperture 32 is typicallycylindrical but can be other shapes.

Within the spacer through aperture 32 is the dielectric 53 in the formof a dielectric spacer 54. The spacer 54 has a cross-sectional shapethat allows a proper fit, mechanically and electrically, in the spaceraperture 32. In the figures, the spacer aperture 32 and spacer 54 areboth round. However, as long as the spacer 54 has the proper impedanceand is structurally sound, the spacer aperture 32 and the spacer 54 canbe different cross-sectional shapes. For example, the spacer aperture 32can be round and the spacer 54 can be octagonal.

Optionally, the spacer aperture 32 and spacer 54 are shaped to preventthe spacer 54 from being pushed through the spacer aperture 32 duringinstallation or if the first environment 1 is at a higher pressure thanthe second environment 2. In general, the first face 54 of the spacer 54is larger than the second opening 36 of the spacer aperture 32. In oneconfiguration, shown in FIG. 24 , the spacer aperture 32 has a steppeddiameter, as at 48, to provide a shoulder 49. The spacer 54 abuts theshoulder 49 to prevent the spacer 54 from falling or being pushedthrough the spacer aperture 32. In another configuration, the spacer 54is a truncated cone rather than cylindrical, similar to the signal link62 of FIG. 21 . The spacer aperture 32 is shaped to match such that,when the spacer 54 is securely within the spacer aperture 32, each end56, 57 located appropriately relative to the corresponding block surface38, 40. Any other geometries that prevent the spacer 54 from beingpushed through the spacer aperture 32 are contemplated by the presentinvention.

The material from which the spacer 54 is made is chosen depending on theapplication. The dielectric constant of the spacer 54 has a valuenecessary to produce a desired impedance environment, usually 50 ohms,although other impedances maybe desired. The dielectric constant canrange from 1.1-15 but usually around 3-4. Typically, the spacer 54 is anengineered plastic (polyetheretherketone, PEEK) that is picked for itsdielectric constant (Dk) value and resulting signal integrityperformance. In one configuration, Dk is 3.3, chosen so that theimpedance of the feedthrough is 50 ohms. Different Dk values can be useddepending on the desired impedance, the diameter of the aperture 32, andthe diameter of the signal link 62.

The spacer 54 has one or more signal through apertures 43 that extendbetween a first opening 44 in the first face 56 and a second opening 45in the second face 57 of the spacer 54. For a coaxial cable 20, there isa single signal aperture 43 that is axially aligned in the spacer 54.For a cable 20 with more than one signal conductor 22, the spacer 54 hasa signal aperture 43 for each signal conductor 22 and the signalapertures 43 are aligned paraxially and arranged for impedance matching,as described below.

The signal link 62 extends through each signal aperture 43. As describedabove, the signal link 62 is an electrically conductive wire or pin.

As described above, the signal link 62 has a first end 65 at the blockfirst surface 38 and a second end 66 at the block second surface 40.Optionally, the signal ends 65, 66 are flush with the correspondingblock surface 38, 40.

As described above, the signal link 62 is typically round, and can beshaped to prevent the signal link 62 from being pushed through thesignal aperture 43 during installation or if the first environment 1 isat a higher pressure than the second environment 2.

The remainder of the present specification is illustrated by theconfiguration with the spacer 54. It is understood that the followingdescriptions also apply to the configuration without the spacer 54 withthe appropriate modification.

Optionally, the aperture 32, spacer 54, and signal link 62 are sized toprovide impedance matching for the signals. Methods for doing so arewell-known in the art, including equations and software simulators, suchas HFSS (high-frequency structure simulator). The key parameters includethe materials, Dk values, and dimensions.

In order for the feedthrough to provide an accurate impedance match, thedielectric 53 must be surrounded by the system ground plane. If theblock 30 is electrically conductive, no special accommodation for theground signal is needed. The block 30 itself is the contact point forthe ground contacts 87 of the connectors 14, 16.

A non-conductive block 30 must feed the ground signal between surfaces38, 40 by a ground coupling 70. This can be accomplished in a number ofdifferent ways.

In one configuration, the ground coupling 70 can include discreteelectrically conductive ground links 71 that extend through groundapertures 72 in the block 30, as in FIGS. 18 and 28 . The ground links71 surround the signal link 62, as in FIGS. 19 and 29 , so that theground signal surrounds the spacer 54/signal link 62. The specificnumber of ground links 71 used to surround the signal link 62 and theirdistances from the signal link 62 will be determined by the parametersof the particular application, such as the desired impedanceenvironment, the diameters of the signal link 62 and spacer 54, and thematerials of which the block 30 and spacer 54 are composed. The groundlinks 71 will typically be arranged equidistantly around a circle thesurrounds the aperture 32. For example, if there are six ground links71, they will be 60° apart, as at 76 in FIGS. 19 and 29 .

The ground links 71 are electrically conductive wires or pins and can becomposed of any electrically conductive material adequate to theapplication. Typically, the ground links 71 will be composed of a copperalloy. In one configuration, the ground links 71 are composed ofberyllium copper plated with gold over nickel. If nonmagnetic groundlinks 71 are desired, gold plated beryllium copper can be used. Theground links 71 can also be composed of non-electrically conductivematerials as long as the ground links 71 can conduct electricity. Forexample, the ground links 71 can be composed of a non-electricallyconductive plastic or composite that is embedded or coated withelectrically conductive materials that render the ground links 71electrically conductive.

Optionally, the ground links 71 and ground apertures 72 are shaped toprevent the ground links 71 from being pushed through the groundapertures 72 during installation or if the first environment 1 is at ahigher pressure than the second environment 2. The same geometriesdescribed above with reference to the signal link 62 can be used. Forexample, each ground link first end 80 has a head 78 that has a largerdiameter than the rest of the ground link 71, as shown in FIG. 20 .

Where the block 30 is of a PCB structure or composed of other dielectricmaterial, the ground links 71 can be vias 73 through the block 30 thatare plated, as at 74 in FIG. 30 , to carry the ground signal through theblock 30. The plated vias 73 surround the signal link 62 as describedabove and typically connect ground planes 79 on both surfaces 38, 40, asin FIGS. 30 and 31 . The plated vias 73 are hermetically sealed byfilling them with a potting material, such as an epoxy, as at 75, orsolder.

The ground link ends 80, 81 are the contact points for the groundcontacts 87 of the connectors 14, 16. In the case of vias 73, theplating 74 can be extended horizontally along the surface 38, 40 of thePCB to provide the contact points 80, 81 for the ground contacts 87.

In another configuration of the ground coupling 70, an electricallyconductive ground ferrule 64 is installed in a ground ferrule throughaperture 84 in the block 30 and the spacer 54 is installed in the spaceraperture 32 in the ground ferrule 64 such that the ground ferrule 64surrounds the spacer 54, as in FIG. 32 . The first end 82 of the groundferrule and the first end 65 of the signal link 62 are flush and thesecond end 83 of the ground ferrule 64 and the second end 66 of thesignal link 62 are flush. The term “flush” is intended to have the samemeaning at described above, where the ferrule ends 82, 83, as beactually flush with, slightly recessed into, or slightly protruding fromthe associated block surface 38, 40.

The ferrule ends 82, 83 are the contact points for the ground contacts87 of the connectors 14, 16. The ground ferrule 64 may be a differenttotal height than the spacer 54 it is installed in. Preferably, theferrule faces 82, 83 and signal link ends 65, 66 protrude from thecorresponding block surface 38, 40, thereby ensuring good compressioncontact with the signal contact 86 and ground contacts 89.

In another configuration of the ground coupling 70, the wall 41 of thespacer aperture 32 is coated with a conductive material. For example, ifthe block 30 is a PCB, the spacer aperture 32 can be a plated via, as at77 in FIG. 33 , where the plating 77 is electrically connected toground. The coating 77 can cover the entire wall 41 or can coat onlypart of the wall 41, for example, as stripes extending between the blocksurfaces 38, 40.

Optionally, the plating 77 in the spacer aperture 32, shown in FIG. 33 ,can be extended horizontally along the surface of the PCB to providecontact points 78 for the ground contacts 87 of the connectors 14, 16.

The signal link 62, ground coupling 70, and, when employed, the spacer54 are installed with a hermetic seal to hermetically separate the twoenvironments 1, 2. The hermetic seal can be formed in one or more ofseveral different ways.

In the first, the various components are press fit into thecorresponding apertures, leaving no gap between adjacent components. Forexample, with the insulating block 30, the signal link 62 is press fitinto the signal aperture 43, leaving no gap between the signal link 62and block 30. With the conductive block 30, the signal link 62 is pressfit into the spacer signal aperture 43, leaving no gap between thesignal link 62 and the spacer 54, and the spacer 54 is press fit intothe spacer through aperture 32, leaving no gap between the spacer 54 andthe block 30. Alternatively, the spacer 54 is molded around the signallink 62 and the spacer 54/signal link 62 combination is press fit intothe spacer through aperture 32. Alternatively, the signal link 62 isheld in the spacer through aperture 32 by a fixture and the spacermaterial is injected into the spacer through aperture 32 around thesignal link 62 to form the spacer 54.

Optionally, the spacer 54 is composed of a slightly compressiblematerial so that, when the spacer 54 is installed in the spacer aperture32, the spacer 54 expands against the spacer aperture wall 41 andagainst the signal link 62 to form the hermetic seal.

In the second method of providing a hermetic seal, shown in FIG. 24 ,the spacer 54 is shorter than the spacer aperture 32 so that both faces56, 57 of the spacer 54 are recessed from the corresponding blocksurface 38, 40, thereby leaving a first gap 58 between the spacer firstface 56 and the block first surface 38 and a second gap 59 between thespacer second face 57 and the block second surface 40. Alternatively,only one face 57 is recessed from the block surface 40, leaving only onegap 59, and the opposite spacer face 56 extends to the correspondingblock surface 38, as in FIG. 26 . Alternatively, only the other face 56is recessed from the block surface 38, leaving only one gap 58, and theopposite spacer face 57 extends to the corresponding block surface 40,as in FIG. 27 .

One or both of the gaps 58, 59 are potted, as at 60, to seal the spaceraperture 32 and around the signal link 62, thereby producing a hermeticseal. The typical potting material is a two-part epoxy, but any materialthat provides the desired seal and is minimally affected by theenvironment can be used. The minimum depth for each gap 58, 59 that willprovide an adequate hermetic seal depends on the environment and thepotting material. In one configuration, the gap depth is approximately0.02 inch and not less than 0.01 inch.

Most of the figures show that the potting material 60 is flush with theblock surfaces 38, 40, although this is not required. The pottingmaterial 60 can be recessed in the gaps 58, 59, as in FIG. 27 . Becausethe potting material 60 is initially liquid, it may form a meniscus 68on its surface.

Plated vias 73 are hermetically sealed by filling them with the pottingmaterial, as at 75 in FIG. 30 , or solder.

One method of potting involves applying a vacuum to one surface 40 ofthe block 30 and allowing the vacuum to pull the potting material 60from the opposite side, thereby forcing the potting material 60 into thegap 58 and all of the interfaces between components, such as between thesignal link 62 and the spacer 54 or block 30, between the spacer 54 andblock 30, and between each ground link 71 and block 30. The vacuumassures that the potting material 60 is forced into all of the spacesthat would provide a leak path between the two environments 1, 2. Ofcourse, the vacuum can be applied in the opposite direction, from theother surface 38.

In another method of potting, pressure is applied to the pottingmaterial at one surface 38, 40 to push the potting material 60 into allof the spaces that would provide a leak path between the twoenvironments 1, 2.

The press fit and potting methods can be employed simultaneously. Forexample, the shorter spacer 54 of FIG. 24 is sized to be press fit intothe aperture 32 and the signal link 62 is press fit into the signalaperture 43, and then the gaps 58, 59 are potted.

The present invention contemplates that the flange 12 is the block 30,that is, the feedthroughs 11 extend through the flange 12 itself, as inFIGS. 34 and 35 .

Alternatively, the block 30 is an independent component that ishermetically sealed into an opening 50 in the flange 12. The block 30can be similar to a connector body or the block 30 can be a printedcircuit board. With the former, there may be more than one block 30mounted in the flange 12, as in FIG. 36 . With the later, typically, asingle PCB is mounted into the flange 12, as in FIG. 37 , although morethan one PCB can be used, as in FIG. 36 . The block 30 is mounted intothe opening 50 by whatever means is appropriate, such as by screws orother mechanical means. The seam between the block 30 and flange 12 canbe potted to provide a hermetic seal. Alternatively, a gasket can beused to provide the hermetic seal.

The connectors 14, 16 removably connect to the feedthrough block 30. Thetypical connection mechanism is via jackscrews 290, shown in FIG. 38 .The jackscrews 290 extend through holes 292 in the anchor block 88 andturn into threaded holes 294 in the feedthrough block 30.

Another embodiment is shown in FIGS. 39-41 . The feedthrough block 30 isthe anchor block 88 of a connector 14. The anchor block 88 is mounted tothe opening 50 in the flange 12 with an O-ring 210 to provide thehermetic seal. Preferably, the connector 14 is mounted to be removablefrom the flange 12. Jackscrews 212 extend through holes 214 in theflange 12 and turn into threaded holes in the anchor block 88.

The cable holes 91 of the anchor block 88 are also hermetically sealed.If the cable 20 is permanently attached, the attachment means(soldering, crimping, potting with a conductive adhesive, insertmolding) provides the hermetic seal. If the cable 20 is removablyattached in the cable holes 91, the cable holes 91 are potted tohermetically seal them after the cable 20 is installed.

The connectors 14, 16 removably connect to each other with a singleplate 89 that is attached to the removable connector 16. The typicalconnection mechanism is via jackscrews 290. The jackscrews 290 extendthrough holes 292 in the anchor block 88 of the removable connector 16and turn into threaded holes 296 in the anchor block 88 of the connector14 mounted to the flange 12, as in FIG. 41 .

The present invention contemplates signals much closer together than canbe had with SMAs or SMPs, thereby increasing the total channel densitygreatly. Signal spacing can be 0.1 inch or smaller, making density ofchannels more than double the current state of the art.

Material and construction are picked for mechanical integrity due toenvironmental pressures and cycle life, minimizing the leak rate as muchas possible, ensuring the intended controlled impedance, and minimal outgassing. The thickness of the block 30 is driven by the mechanicalstrength of the block material. In the case of one environment being ata different pressure than the other environment, the block 30 must bethick enough to stay relatively flat, for example, +/−0.01 inch over thearea of the surfaces 38, 40 in order to insure a proper mating face.Otherwise, the thickness of the block 30 is not critical.

Thus, it has been shown and described a hermetically sealed controlledimpedance feedthrough assembly. Since certain changes may be made in thepresent disclosure without departing from the scope of the presentinvention, it is intended that all matter described in the foregoingspecification and shown in the accompanying drawings be interpreted asillustrative and not in a limiting sense.

The invention claimed is:
 1. A controlled impedance feedthrough assemblybetween a first environment and a second environment, the feedthroughassembly comprising: (a) an electrically conductive block having a firstsurface and a second surface; (b) at least one feedthrough in the blockextending between the first surface and the second surface, thefeedthrough comprising: (1) a spacer through aperture extending betweenthe first surface and the second surface; (2) a dielectric spacer withinthe spacer through aperture having a first face and a second face; (3) asignal through aperture extending between the first face and the secondface; and (4) a rigid, electrically-conductive signal link in the signalthrough aperture having a first end at the first surface and a secondend at the second surface; (c) the feedthrough being hermetically sealedby one of either the first face being recessed from the first surfaceforming a first gap that is filled with a potting material or the secondface being recessed from the second surface forming a second gap that isfilled with the potting material.
 2. The controlled impedancefeedthrough assembly of claim 1 wherein the first gap or the second gapis at least 0.01 inch in depth.
 3. The controlled impedance feedthroughassembly of claim 1 wherein the potting material is an epoxy.
 4. Thecontrolled impedance feedthrough assembly of claim 1 further comprisinga flange separating the first environment and the second environment,the block being mounted within an opening in the flange, the seambetween the block and flange being hermetically sealed.
 5. Thecontrolled impedance feedthrough assembly of claim 1 wherein the signallink and signal through aperture are shaped to prevent the signal linkfrom being pushed through the signal through aperture and wherein thespacer and spacer aperture are shaped to prevent the spacer from beingpushed through the spacer aperture.
 6. The controlled impedancefeedthrough assembly of claim 5 wherein the first end of the signal linkhas a head with a larger diameter than a diameter of the signal throughaperture.
 7. The controlled impedance feedthrough assembly of claim 5wherein the spacer aperture has a stepped diameter creating a shouldersuch that a diameter of the first opening is larger than the diameter ofthe second opening, and wherein the spacer abuts the shoulder.
 8. Acontrolled impedance feedthrough assembly between a first environmentand a second environment, the feedthrough assembly comprising: (a) anelectrically conductive block having a first surface and a secondsurface; (b) at least one feedthrough in the block extending between thefirst surface and the second surface, the feedthrough comprising: (1) aspacer through aperture extending between the first surface and thesecond surface; (2) a dielectric spacer within the spacer throughaperture having a first face and a second face; (3) a signal throughaperture extending between the first face and the second face; and (4) arigid, electrically-conductive signal link in the signal throughaperture having a first end at the first surface and a second end at thesecond surface; (c) the feedthrough being hermetically sealed by atleast one of the first face being recessed from the first surfaceforming a first gap and the second face being recessed from the secondsurface forming a second gap, and at least one of the first gap andsecond gap being filled with a potting material.
 9. The controlledimpedance feedthrough assembly of claim 8 wherein the first gap or thesecond gap is at least 0.01 inch in depth.
 10. The controlled impedancefeedthrough assembly of claim 8 wherein the potting material is anepoxy.
 11. The controlled impedance feedthrough assembly of claim 8further comprising a flange separating the first environment and thesecond environment, the block being mounted within an opening in theflange, the seam between the block and flange being hermetically sealed.12. The controlled impedance feedthrough assembly of claim 8 wherein thesignal link and signal through aperture are shaped to prevent the signallink from being pushed through the signal through aperture and whereinthe spacer and spacer aperture are shaped to prevent the spacer frombeing pushed through the spacer aperture.
 13. The controlled impedancefeedthrough assembly of claim 12 wherein the first end of the signallink has a head with a larger diameter than a diameter of the signalthrough aperture.
 14. The controlled impedance feedthrough assembly ofclaim 12 wherein the spacer aperture has a stepped diameter creating ashoulder such that a diameter of the first opening is larger than thediameter of the second opening, and wherein the spacer abuts theshoulder.